5-Axis Laser Cutting System for Cranial Implants Modification

/ Overview

Design and development of a compact 5‑axis laser cutting system automatically resizes customized cranial implants for single-stage cranioplasty. The system enables precise three-dimensional trimming of complex cranial or craniofacial implant geometries within a sterile operating-room environment, overcoming the limitations of manual, surgeon-dependent reshaping. Preliminary experimental results demonstrate superior implant fit, with millimeter-scale gaps between the implant and cranial defect, indicating operative duration reductions and improved aesthetic asymmetry.

/ Key Contributions

• Designed and engineered a novel 5‑axis laser cutting machine specifically optimized for intraoperative, single-stage cranioplasty implant modification
• Developed a three-dimensional shaping approach that accurately bevels implant edges and accommodates complex cranial or craniofacial geometries beyond the capabilities of conventional laser cutters
• Demonstrated, through preliminary experiments, that the system achieved higher-quality implant–skull fit with only millimeter-level gaps, reduced operative duration, and improved cosmetic outcomes